Smart TM Yard and Smart TM Production. Arne Monsholm Vice President Business Development

Transcription

1 Smart TM Yard and Smart TM Production Arne Monsholm Vice President Business Development

2 HEXAGON Geosystems Metrology 15,000+ people 3B revenue 3,200 active patents

3 Intergraph Process, Power & Marine 2200 Employees in 64 countries 550 mill USD Revenue Industries served Oil and Gas Chemical Power Refining Marine and Offshore Mining and Metals

4 INTERGRAPH OFFERS SOLUTIONS FOR THE ENTIRE LIFECYCLE BASIC/FEED DETAIL DESIGN PROCUREMENT & MATERIALS FABRICATION CONSTRUCTION OPERATION, REVAMP & DECOMMISSIONING

5 Automation and implementation services BETTER SOLUTIONS FOR BETTER FACILITIES Engineering & Schematics 3D Design & Visualization Analysis Procurement, Fabrication & Construction Alliances & Partners Smart P&ID Smart Instrumentation Smart Electrical Smart Process Safety Smart Isometrics SmartSketch Smart 3D PDS/Frameworks Plus Smart Review Smart Interop Publisher Smart FreeView CAESAR II PV Elite TANK GTStrudl FEATools NozzlePro Visual Vessel Design (VVD) Smart Materials Technology members Smart Reference Data Service members Smart Spoolgen Content members Smart Construction Complementary solutions Smart WQMS Smart Production powered by Nestix INTEGRATION AND INFORMATION SmartPlant Foundation, Smart Data Validator, Smart Fusion, Smart Basic Integrator

6 Typical Fabrication Facility Challenges CAD System formats Change Management Material Production Flow Remnant & Material Management Available Resource usage Schedule Real Time Information Quality

7

8 Work Process based solutions

9 Project Control Planning Construction Shop Floor Mgmt System Completion & Handover Catalogues & Materials Digital BOM Welds & QC 2D & 3D Design Documents & Data Virtual Assembly

10 HANDOVER DOSSIER TREE MATERIAL ISSUE HANDOVER DATA/DOCUMENT WAREHOUSE DESIGN ANALYSIS TRANSMITTALS MATERIAL RECEVING DASHBOARD PROGESS REMNANT CAPITAL PLANNING WIRING PRODUCTION DRAWINGS REPORTING ELECTRONIC WORKFLOWS SUB CON. DIGITAL BOM 2D AND 3D REPORTING POST WELD HEAT TREATMENT MACHINE INTERFACE EARNED VALUE INTRUMENTS INDEX PRODUCTION PLANNING WELD DETAILS ONLINE MARKUP PURCHASE ORDER TRANSPORTATION SUPPORT 4D ANIMATION NON DESTRUCTIVE TESTING LOAD BALANCING PUNCH LIST PROGRESS POWER DISTRIBUTION CABLE ROUTING & PIPE CUT LENGTH PROGRESS SUPPLIER LIFTING LUGS CONSTRUCTION PLANNING OF VISUAL INSPECTION INTERNAL LOGISTICS CHECKLIST PROGRESS SINGLE LINE DIAGRAM OUTFITTING BiILL-OF- MATERIAL ENG. CHANGE PURCHASE REQUISITION SCAFFOLDING RULES OF PROGRESS FIT-UP QUEUE MECHNICAL COMPLEION CHANGE CONTROL SINGLE LINE DIAGRAM STRUCTURE SPOOL DRAWING ASSET DATA BOM ESTIMATION & BUILDING STRATEGY WORKPACK CREATION MATERIAL VERIFICATION PANEL WELDING PRE-MECH. COMPLETION CONTRACT PIPING & HVAC DIAGRAM SCHEMATIC INTEGRATION ISOMETRIC DRAWING DOCUMENT CATALOG WORKPACK AUTOMATION MATERIAL ENGINEERING SCHEDULE WELDER DATABASE NESTING PLATE/PROFILE/PIPE SYSTEM & SUB- SYSTEM DEFINITION BUDGETTING AND FORECASTING SCHEMATICS 2D/3D MODEL SPOOLING DATA & DOCUMENT MATERIAL PRODUCTION PLANNING CONSTRUCTION WELD QUALITY PRODUCTION MANAGEEMNT SYSTEM COMPLETION PROJECT CONTROL YARD ENGINEERING DOCUMENT MATERIAL PLANNING DATA & ESTIMATION CONSTRUCTION WELD QUALITY SHOP FLOOR COMMISIONING AND TESTING

11 Supporting the fabrication process flow Engineering data Work preparation Assembly structures Part geometries Schedule Production routing Capacity planning Part nesting Change management Work management Prefabrication INDUSTRY 4.0 Smart Factory Workshop sequencing and balancing Queueing work phases Guidance for shop floor INDUSTRIAL Cutting LEAN INTERNET Manufacturing Part fabrication Panel and assembly production Internal logistics

12 Supporting the principles of LEAN production Eliminate waste Effective material utilization Minimize inventory Optimized reservation of material Thin material flow in process Maximize production flow Detect and control bottlenecks Full data system integration reduces lead times in production Pull production from the demand Produce according to actual need Meet customer requirements Real time work status of production Do it right the first time Process improves the quality of the whole steel production flow Empower workers Operators have access to real time data to make right decisions Design for rapid changeover Task list for each operator and autonomy to make use of it Partner with key suppliers Suppliers may interact electronically Create a culture of continuous improvement (Kaizen) Data collection and visualization Process development

13 Change Management Design changes (geometry, material grade, thickness, profile type) Changes in received and forecasted material SmartProduction has embedded change management with automatic flagging and color coding The consequences of changes in production will be controlled depending on the status of the production and type of change Cutting module Order module

14 Material Forecast & Verification

15 Production Scheduling (Level 4 and beyond) Geometry based Capacity Need Calculation Backwards/forwards planning Order Production Scheduling Scheduling Rules Work Queue Scheduling Work Queue Comprehensive Calendar System Work Load Visualization Work Load Schedule to achieve thin (Lean) material flow in production Work Load & Work Queue

16 Data Feedback from Shop Floor Parts fabrication follow-up PC Sub-spools assembly follow-up Sub-spools assembly follow-up Final spools assembly follow-up PC PC PC Parts fabrication follow-up PC PC PC Smart Production PC Overall production planning & monitoring Sub-spools assembly follow-up Final spools assembly follow-up Machinery: 1. Magenta - Sawing Machine 2. Green - Bevel Machine 3. Yellow - Fit-up station 4. Blue - Welding station

17 AUTOMATED FLAT PANEL LINE

18 DESIGN SYSTEM INTERFACES Loop back.xml PlatePart.XML ProfilePart.XML Panel.XML Assembly.XML Pipe Spool.FIX Pipe spool.idf,.pcf,.fix DXF, DSTV

19 Benefits of SmartProduction CAD Neutral Manage changes Maximize Production Flow Save Material Optimize Resource usage Reduce Man-hours Follow Up in Real Time Improve Quality

20